Temperature Measurement & Control Solutions
At Clipper Controls, we provide a full range of temperature measurement and control solutions designed to meet the demanding needs of industrial, utility, and environmental applications. From precise sensor technologies to robust transmitters and controllers, our products help ensure reliable monitoring, accurate process control, and consistent system performance. Whether you're working with high-temperature processes, sensitive environmental conditions, or harsh field environments, we offer proven solutions backed by technical expertise and strong manufacturer partnerships.
Temperature Sensors
We supply a comprehensive selection of temperature sensors to support accurate and reliable measurement across a wide range of industrial applications. Our offering includes thermocouples and RTD sensors—two of the most widely used sensor types in process control—available in multiple configurations and materials to match your system requirements. Whether you need high-temperature durability, rapid response time, or precise measurement accuracy, we can provide the right sensor solution.
In addition to direct-contact sensors, we also offer camera-based infrared temperature sensors for non-contact surface measurement, ideal for moving parts or inaccessible areas. For mechanical systems requiring robust temperature control, we carry filled bulb sensors, commonly used in HVAC and process systems. To protect and extend the life of your sensors in harsh environments, we provide thermowells in a variety of materials and insertion lengths. From standard designs to custom assemblies, Clipper Controls has the sensor technology to meet your operational and environmental needs.
Thermocouples
Application: Thermocouples are rugged and versatile temperature sensors used in high-temperature and dynamic environments. With fast response and the ability to measure up to 1,800°C depending on type, they are commonly installed in combustion systems, heat exchangers, turbines, and exhaust stacks. Their durability under thermal shock and vibration makes them ideal for demanding applications in power plants, refineries, and industrial furnaces.
RTD Sensors
Application: RTDs (Resistance Temperature Detectors) provide precise and repeatable temperature measurement, typically using platinum elements such as PT100 or PT1000. They are preferred in applications requiring high accuracy and long-term stability, including pharmaceutical batch processing, food production lines, and cleanroom manufacturing. RTDs are often installed in sanitary fittings, thermowells, or industrial probes to monitor critical temperature parameters with tight tolerances.
Camera-Based Sensors
Application: Infrared camera sensors capture thermal profiles without direct contact, enabling safe and continuous monitoring of hot or hazardous surfaces. These sensors are used in process monitoring, predictive maintenance, and quality control, particularly for rotating machinery, live electrical components, and web-based material production. Applications include thermal inspection of electrical panels, kiln shell monitoring, and conveyor belt surface profiling.
Filled-Bulb Sensors
Application: Filled-bulb sensors utilize liquid or gas expansion within a sealed system to measure temperature mechanically. These sensors are well-suited for remote sensing locations where electrical power is not available or where environmental conditions call for a passive, mechanical approach. Typical applications include temperature control in air handling units, tank heating systems, and older industrial process setups where electronic components may not be viable.
Thermowells
Application: Thermowells provide critical protection for temperature sensors in pressurized, corrosive, or high-velocity flow environments. They enable insertion of sensors into process media while allowing maintenance or replacement without disrupting operations. Commonly machined from stainless steel, Hastelloy, or other corrosion-resistant alloys, thermowells are specified based on pressure rating, immersion depth, velocity profile, and wake frequency calculations to ensure safe and reliable operation in chemical plants, refineries, and thermal utilities.
Temperature Transmitters
At Clipper Controls, we offer a complete range of temperature transmitters to meet the diverse needs of industrial process monitoring and control. Our portfolio includes analog and digital transmitters compatible with RTDs, thermocouples, and universal inputs, ensuring flexibility for virtually any application. Whether you need a simple 4–20 mA output for a straightforward loop or a smart transmitter with HART or digital Fieldbus communication, we have reliable solutions from trusted manufacturers.
We carry head-mounted transmitters for direct sensor integration, DIN rail-mounted units for panel installations, and robust field-mount options designed for harsh environments. For safety-related processes, our transmitters are available with certified SIL ratings, allowing them to be implemented in safety instrumented systems (SIS) where basic but reliable signal transmission is essential to meet operational risk reduction requirements. For advanced applications, we also offer smart and wireless transmitters with built-in diagnostics, custom scaling, and remote configuration capabilities. From basic temperature signal conversion to full-featured temperature monitoring systems, our team can help specify the ideal transmitter for your process.
Analog & Digital Temperature Transmitters
Application: Analog temperature transmitters convert sensor inputs from RTDs or thermocouples into standardized 4–20 mA output signals for integration with PLCs, DCS, or panel meters. These transmitters are ideal for environments requiring high signal integrity over long cable distances, offering noise immunity and compatibility with legacy systems. Common applications include distributed process loops in refineries, water treatment facilities, and boiler control systems where simplicity, reliability, and low signal latency are critical.
Safety Instrumented Systems (SIS) Temperature Transmitters
Application: Safety Instrumented Systems (SIS) Temperature Transmitters are critical components in process safety applications where temperature monitoring is part of a safety instrumented function (SIF). These transmitters are designed to meet stringent SIL (Safety Integrity Level) requirements per IEC 61508/61511 standards, ensuring reliable performance in high-risk environments. Commonly deployed in chemical processing, oil and gas, power generation, and pharmaceutical manufacturing, SIS-rated transmitters provide continuous temperature data with built-in diagnostics, fault detection, and fail-safe operation. They enable rapid response to abnormal temperature conditions, triggering alarms, shutdowns, or control actions to prevent hazardous events and protect personnel, equipment, and the environment.
Temperature Switches
Clipper Controls offers a full range of temperature switches engineered for dependable thermal protection and process safety. Designed to activate alarms, relays, or shutdown functions when critical thresholds are reached, our switches are available in both mechanical and electronic configurations. Whether safeguarding equipment or automating basic control functions, our temperature switches deliver responsive, reliable performance trusted across industrial and utility applications.
Mechanical Temperature Switches
Application: Mechanical temperature switches provide reliable, passive control in temperature-dependent processes by using physical mechanisms to trigger switching actions. These switches are widely used in HVAC systems, thermal protection circuits, and industrial heating and cooling equipment. Due to their simple construction and lack of electrical requirements for sensing, they are ideal for remote or hazardous environments where electrical components may be limited or undesired. Mechanical temperature switches offer robust operation in high-vibration settings and are often employed as primary or backup safety shutdown devices in thermal process systems.
Electronic Temperature Switches
Application: Electronic temperature switches utilize input from RTDs, thermistors, or thermocouples to monitor temperature and trigger precise switching logic via integrated circuits. With configurable setpoints, relay or analog outputs, and often integrated displays, these switches are used in applications requiring fast response, accuracy, and interface with control systems. They are common in process automation, critical thermal protection, and compact systems where programmable flexibility is required. Many models include self-diagnostics, HART or Modbus communication, and SIL-rated options for integration into safety instrumented systems. Their compact design and digital reliability make them ideal for both OEM installations and industrial retrofits.
Temperature Gauges
We provide temperature gauges built for durability, accuracy, and clear local indication. Our lineup includes bimetallic, gas-actuated, liquid-filled, and digital models, supporting everything from general plant monitoring to specialized thermal diagnostics. Designed for harsh field conditions and easy integration into your systems, our temperature gauges ensure operators have instant visibility into process status—no power required.
Bimetallic Temperature Gauges
Application: Bimetallic temperature gauges utilize the mechanical deflection of a coiled bimetallic strip to provide direct temperature indication without requiring external power. These gauges are ideal for rugged mechanical applications such as boilers, hydraulic systems, and HVAC equipment. Their robust construction ensures reliable performance in high-vibration environments, while their cost-effectiveness and simplicity make them well-suited for general-purpose temperature monitoring across a wide operating range.
Gas-Actuated Temperature Gauges
Application: Gas-actuated temperature gauges operate on the principle of pressure change within a sealed gas-filled system, enabling accurate temperature readings even over long capillary distances. With a fast response and stable readings across wide temperature ranges, these gauges are commonly used in tanks, pipelines, heat exchangers, and remote process locations. Their ability to maintain accuracy under harsh operating conditions makes them an excellent choice for applications in power generation, chemical processing, and heavy industry.
Liquid-Filled / Vapor-Tension Gauges
Application: Liquid-filled and vapor-tension gauges measure temperature via fluid expansion in a sealed bulb and capillary assembly. These gauges are particularly well-suited for applications where remote sensing and high shock resistance are required, such as in refrigeration systems, ovens, industrial tanks, and rotating machinery. The filled system damps vibrations and protects the internal mechanism, making it reliable in high-cycle and turbulent environments.
Digital Temperature Gauges
Application: Digital temperature gauges combine precision electronic sensing—typically using RTDs, thermocouples, or thermistors—with digital readouts for high-accuracy, real-time measurement. They are widely used in process control systems, laboratory environments, and equipment calibration where tight tolerances and clear display are essential. Many models include features such as configurable alarms, signal outputs, and data logging, supporting both standalone and integrated monitoring applications.
Infrared Temperature Gauges
Application: Infrared temperature gauges provide non-contact temperature measurement by detecting emitted thermal radiation from a surface. They are ideal for applications where contact sensing is impractical or unsafe, such as moving equipment, live electrical systems, food production lines, and rotating machinery. With rapid response times and no need for physical installation at the point of measurement, IR gauges offer a reliable solution for spot-checking and continuous monitoring in hard-to-access or hazardous areas.
Temperature Controllers
Clipper Controls delivers temperature controllers that bring precision and reliability to your thermal processes. From basic on/off control to advanced PID and multi-loop automation, our solutions help maintain critical temperature setpoints across manufacturing, research, and energy sectors. With models offering digital integration, SIL-rated protection, and ramp/soak capabilities, our controllers provide the flexibility to meet both standard and highly dynamic application demands.
On/Off Temperature Controllers
Application: On/Off temperature controllers provide a basic form of thermal regulation by switching output devices fully on or off in response to temperature deviations from the setpoint. This binary control method is ideal for non-critical applications with slow thermal response, such as water heaters, food warming equipment, and small ovens. While cost-effective and easy to implement, On/Off control can result in temperature oscillation (hysteresis) around the setpoint and is generally not suitable for precision processes or systems with rapid thermal cycling.
Proportional (P) Controllers
Application: Proportional controllers regulate output based on the magnitude of deviation from the temperature setpoint, delivering a control signal that varies linearly with process error. These controllers are suited for applications requiring smoother control than basic on/off systems, such as fluid heating loops, non-critical drying processes, and general thermal stabilization. While they improve stability and reduce cycling, P-only controllers typically exhibit a steady-state error or offset under constant load. They are often used in simple systems where minor deviation is acceptable and where integral control may not be necessary.
Proportional-Integral (PI) Controllers
Application: PI controllers combine the fast corrective action of proportional control with an integral function that eliminates long-term steady-state error. This control method is ideal for thermal systems where accuracy over time is essential but process conditions are relatively stable. PI controllers are widely applied in heat exchangers, reactor jackets, and temperature-sensitive flow systems where precise regulation is required without the added complexity or sensitivity of derivative action. Their balanced approach makes them a common default for industrial heating and cooling processes that demand reliable, drift-free control.
Proportional-Integral-Derivative (PID) Controllers
Application: PID (Proportional-Integral-Derivative) controllers offer the most accurate and responsive temperature regulation, using a mathematical control algorithm that continuously adjusts output based on present error, accumulated error over time, and anticipated future error trends. This makes them ideal for complex systems with fast dynamics or sensitive materials—such as industrial furnaces, plastics extrusion lines, and environmental chambers. PID controllers reduce overshoot, improve stability, and ensure precise setpoint maintenance even under variable load conditions. Many models include auto-tuning and adaptive control to optimize performance without manual calibration.
Programmable / Multi-Loop Controllers
Application: Programmable temperature controllers manage multiple independent or cascaded loops and often include advanced features such as ramp/soak profiling, data logging, alarm outputs, and recipe management. These controllers are used in batch processing, environmental test chambers, industrial kilns, and any system requiring time-based thermal control or process sequencing. With Ethernet, Modbus, and analog output options, they can operate as standalone logic units or as part of a distributed control system. Their scalability and configurability make them a flexible solution for complex thermal control environments.
Safety Limit Controllers (High-Limit / Low-Limit)
Application: Safety limit controllers serve as independent protection devices, triggering a system shutdown if the process temperature exceeds a high or low safety threshold. These are critical in applications with elevated risk or regulatory requirements, such as heat treat furnaces, sterilizers, autoclaves, and fuel-fired heaters. Often used in conjunction with PID control loops, SIL-rated limit controllers provide an additional layer of safety by acting as a failsafe that cannot be overridden by normal control logic. Their use supports compliance with IEC 61508/61511 standards in Safety Instrumented Systems (SIS).
Temperature Instrumentation Applications
Municipal Water & Wastewater Treatment Applications
Temperature monitoring is essential across many stages of water and wastewater treatment to optimize performance, protect equipment, and meet regulatory standards. Below are key applications along with the types of temperature instrumentation commonly used:
- Biological Treatment Processes (Aeration & Activated Sludge)
Purpose: Monitor basin temperature to ensure optimal microbial activity and biological reaction rates.
Instrumentation Used: RTD sensors or thermocouples integrated with transmitters for continuous monitoring. Data is typically fed into SCADA or PLC systems for trend analysis and process optimization. - Anaerobic Digestion
Purpose: Maintain proper temperature within digesters to support methane production and stable digestion performance.
Instrumentation Used: High-accuracy RTDs with thermowells, paired with PID controllers or temperature transmitters. Monitoring is critical for both mesophilic and thermophilic digestion regimes. - Disinfection & Chlorination
Purpose: Adjust chemical dosing based on temperature, as disinfection efficacy can vary with water temperature.
Instrumentation Used: Compact RTDs or thermistors with transmitters used to provide real-time temperature data for chemical feed control logic. - Sludge Treatment & Dewatering
Purpose: Monitor and control temperature during sludge thickening and thermal conditioning to improve solids handling and energy recovery.
Instrumentation Used: Industrial-grade RTDs with remote transmitters or local indicators installed in sludge lines or thermal treatment chambers. - Effluent Monitoring & Environmental Compliance
Purpose: Track final effluent temperature prior to discharge to comply with thermal pollution limits and NPDES permit requirements.
Instrumentation Used: In-line thermocouples or immersion sensors with data logging capabilities. Often integrated into compliance monitoring systems. - Freeze Protection & Equipment Monitoring
Purpose: Detect low ambient or process temperatures to trigger heat tracing or insulation systems, protecting exposed piping and tanks.
Instrumentation Used: Temperature switches and simple on/off controllers tied to local alarm systems or automated heat systems.
Food & Beverage Processing Applications
Temperature control is critical throughout the food and beverage production chain to ensure product quality, regulatory compliance, and operational efficiency. From raw material handling to packaging, temperature impacts food safety, shelf stability, and process performance. Below are key applications along with the types of temperature instrumentation commonly used:
- Pasteurization & Sterilization
Purpose: Ensure that temperature reaches and maintains required thresholds to eliminate harmful microorganisms and extend shelf life.
Instrumentation Used: High-accuracy RTDs or sanitary thermocouples installed in process lines and heat exchangers, often paired with PID controllers and data loggers to meet HACCP and FDA validation requirements. - Cooking, Baking, and Thermal Processing
Purpose: Maintain precise temperature profiles for consistent product texture, flavor, and doneness across batches.
Instrumentation Used: Insertion thermocouples and RTDs with programmable controllers and ramp/soak capabilities to follow time-temperature recipes. Infrared sensors may be used for non-contact surface monitoring in conveyor ovens. - Fermentation & Culturing
Purpose: Monitor and control temperature in fermentation tanks to support microbial growth and biochemical reactions.
Instrumentation Used: Sanitary RTDs or thermistors integrated into fermentation vessels with temperature transmitters and local or remote PID controllers for tight regulation. - Chilling & Freezing
Purpose: Rapidly reduce temperature of products to inhibit microbial growth and preserve freshness.
Instrumentation Used: Thermocouples or RTDs used in blast chillers, freezers, and glycol systems, often tied to SCADA systems or refrigeration controls to monitor system response and ensure cold chain integrity. - CIP (Clean-in-Place) Systems
Purpose: Verify that cleaning cycles reach required temperatures to ensure sanitation of tanks, piping, and process equipment.
Instrumentation Used: RTDs in hygienic fittings with digital transmitters and data acquisition systems for traceability and validation of thermal cleaning cycles. - Packaging & Sealing Operations
Purpose: Control sealing temperatures to ensure proper packaging integrity and prevent spoilage or contamination.
Instrumentation Used: Embedded thermocouples with high-speed controllers on heat-sealing equipment, ensuring consistent performance and reducing waste. - Storage & Cold Chain Monitoring
Purpose: Monitor storage conditions for temperature-sensitive products during warehousing and transportation.
Instrumentation Used: Wireless temperature sensors, data loggers, and digital gauges installed in refrigerated storage and transport units to maintain compliance and quality assurance.
Life Science & Pharmaceutical Applications
Precise temperature monitoring is critical in the life sciences and pharmaceutical industries to maintain product integrity, support regulatory compliance, and ensure process repeatability. From R&D laboratories to large-scale production, temperature plays a key role in every stage of the workflow. Below are key applications and the instrumentation used:
- Bioreactors & Fermentation Vessels
Purpose: Maintain tightly controlled temperature environments to optimize biological growth and reaction kinetics during cell culture and fermentation.
Instrumentation Used: High-accuracy RTDs in hygienic fittings, often with redundant sensors and transmitters integrated into validated control systems. PID controllers with alarm and logging functions are standard to ensure stability and traceability. - Lyophilization (Freeze-Drying)
Purpose: Monitor and control temperature during sublimation and secondary drying phases to protect product structure and efficacy.
Instrumentation Used: Thermocouples with high-speed controllers and data acquisition systems are used inside freeze-dry chambers. Sensor mapping and validation procedures ensure uniform temperature profiles during critical drying stages. - Cold Storage & Vaccine Freezers
Purpose: Ensure temperature stays within strict limits for storage of temperature-sensitive drugs, vaccines, and biologics.
Instrumentation Used: RTDs or thermistors connected to wireless transmitters or data loggers. Alarm systems with SMS/email notification and cloud integration are common for compliance with CDC and WHO cold chain requirements. - Autoclaves & Sterilization Chambers
Purpose: Verify that sterilization cycles meet temperature and exposure time requirements for validated cleaning and decontamination.
Instrumentation Used: Thermocouples or RTDs placed in load probes and chamber walls, connected to validated controllers and monitoring systems. Redundant sensors and independent safety limit controllers are often used for added assurance. - Cleanroom Environmental Monitoring
Purpose: Monitor ambient temperature in cleanroom environments to maintain consistent conditions and meet GMP or ISO standards.
Instrumentation Used: Wall-mounted RTDs or digital temperature sensors with BACnet or Modbus communication. Integrated into building management systems (BMS) with continuous logging and audit trail capabilities. - Research & Stability Chambers
Purpose: Simulate long-term storage and shelf-life conditions for pharmaceuticals under controlled temperature profiles.
Instrumentation Used: RTDs with transmitters tied into programmable environmental chambers, featuring multi-point mapping and precise ramp/soak control for stability studies and ICH compliance. - WFI (Water for Injection) Systems
Purpose: Monitor hot water temperatures to ensure compliance with USP and EU Pharmacopoeia standards for WFI generation and distribution.
Instrumentation Used: Sanitary RTDs or thermocouples installed in-line with transmitters. Data logging and SCADA integration provide validation-ready temperature records.
Power Generation & Energy Applications
In the power generation and energy sectors, temperature is a critical process variable that affects safety, efficiency, and equipment longevity. From turbine systems to thermal energy storage, temperature instrumentation ensures that systems operate within design parameters, helping reduce downtime and prevent catastrophic failures. Below are key applications and the instrumentation used:
- Turbine Inlet & Exhaust Monitoring
Purpose: Measure combustion and exhaust temperatures to protect turbine components, optimize performance, and comply with emissions standards.
Instrumentation Used: High-temperature thermocouples (e.g., Type K or N) installed at critical monitoring points, often with rugged protection sheaths and fast-response tips. Data is transmitted to DCS or turbine control systems for real-time diagnostics and performance tuning. - Boiler and Steam Drum Monitoring
Purpose: Maintain precise temperature control in water walls, steam drums, and superheaters to optimize steam quality and thermal efficiency.
Instrumentation Used: Thermocouples and RTDs in high-pressure wells or welded fittings, with 4–20 mA transmitters integrated into safety interlocks and closed-loop controls. - Heat Recovery Steam Generators (HRSGs)
Purpose: Monitor flue gas and feedwater temperatures to manage thermal gradients and avoid material fatigue in combined cycle plants.
Instrumentation Used: Multiple point thermocouple arrays and RTDs, monitored via programmable logic controllers (PLCs) or distributed control systems (DCS). Temperature switches are also used for high-temperature trip alarms. - Generator Bearing & Winding Temperature
Purpose: Detect overheating in generator bearings, stators, and windings to prevent insulation failure and unplanned outages.
Instrumentation Used: Embedded RTDs or thermistors with digital transmitters. Temperature limit controllers are often included for shutdown protection or alarm signaling. - Thermal Energy Storage & Solar Thermal Systems
Purpose: Regulate heat transfer fluid (HTF) and molten salt temperatures to maximize energy storage capacity and system efficiency.
Instrumentation Used: RTDs with remote-mount transmitters designed for extreme temperatures and corrosive fluids. Instruments are often networked for control room visibility and SCADA integration. - Transformer & Substation Monitoring
Purpose: Measure oil and winding temperatures to assess transformer load conditions and extend asset life.
Instrumentation Used: Analog and digital temperature gauges, RTDs, and thermal switches installed in transformer tanks. Data is transmitted via hardwired or wireless condition monitoring systems. - Cooling Water Systems & Condensers
Purpose: Monitor inlet and outlet temperatures to assess heat exchanger performance and prevent fouling or scaling.
Instrumentation Used: Insertion RTDs and thermocouples with weatherproof transmitters and local displays. Often connected to automated blowdown or chemical treatment systems.
Chemical & Petrochemical Applications
Temperature control is fundamental to the safe and efficient operation of chemical and petrochemical processes. From reaction kinetics and distillation to storage and emissions control, precise temperature measurement is essential for maintaining product quality, preventing runaway reactions, and meeting regulatory requirements. Below are key applications and the instrumentation used:
- Reaction Vessel Monitoring
Purpose: Control exothermic and endothermic reactions by maintaining precise temperature profiles within reactors.
Instrumentation Used: RTDs or thermocouples installed in thermowells or jacketed vessels. Often paired with PID controllers and remote-mount transmitters connected to DCS systems for closed-loop control. - Distillation Columns
Purpose: Monitor column temperature gradients to optimize separation efficiency and control overhead and bottom product purity.
Instrumentation Used: Multipoint thermocouple assemblies or RTDs installed at strategic column locations, with data integrated into advanced process control systems. - Heat Exchangers
Purpose: Ensure efficient heat transfer and detect fouling or scaling conditions by monitoring inlet and outlet temperatures.
Instrumentation Used: Insertion-style RTDs or thermocouples, typically installed in both process and utility streams. Transmitters feed data into plant-wide performance monitoring systems. - Tank Heating & Temperature Maintenance
Purpose: Maintain storage tank temperatures to prevent product solidification or phase separation, especially for high-viscosity chemicals.
Instrumentation Used: Thermocouples or RTDs installed through tank walls or in thermal wells, with feedback to temperature switches or local control panels to regulate electric heat tracing or steam systems. - Emissions & Flare Stack Monitoring
Purpose: Measure combustion efficiency and temperature at the flare tip to ensure safe operation and compliance with emissions regulations.
Instrumentation Used: Infrared temperature sensors or high-range thermocouples in thermowells with flame arrestors. Data is logged and used for combustion diagnostics and EPA reporting. - Pipelines & Process Lines
Purpose: Monitor temperature to detect line blockages, freezing, or reaction zone stability in continuous processes.
Instrumentation Used: Inline RTDs or clamp-on thermocouples, often paired with wireless transmitters or local indicators in hazardous-rated enclosures. - Batch Reactor Safety Systems
Purpose: Provide over-temperature protection in batch reactors to prevent thermal runaway and equipment damage.
Instrumentation Used: SIL-rated temperature switches or limit controllers with redundant RTDs, integrated into safety interlock systems per IEC 61508/61511 standards.
Mining & Minerals Processing Applications
In mining and mineral processing operations, temperature measurement is essential for maintaining process stability, ensuring worker safety, and protecting equipment from thermal stress. From ore extraction and material separation to drying and smelting, reliable temperature instrumentation helps optimize yield, reduce energy consumption, and improve system uptime. Below are key applications and the instrumentation used:
- Ore Drying and Rotary Kilns
Purpose: Monitor and control material and shell temperatures to ensure proper drying, calcining, or roasting in rotary kilns and dryers.
Instrumentation Used: High-temperature thermocouples installed at multiple kiln zones, paired with transmitters and PID controllers. Infrared sensors may be used for non-contact shell temperature measurement. - Flotation and Leaching Tanks
Purpose: Maintain optimal temperature conditions for chemical reactions and separation efficiency during flotation or leaching.
Instrumentation Used: RTDs or thermistors in protective wells, integrated with local displays or control systems. Monitoring supports reagent activity and enhances mineral recovery. - Autoclaves and Pressure Oxidation Reactors
Purpose: Monitor internal temperatures under high pressure to ensure reaction control and metallurgical recovery in hydrometallurgical processes.
Instrumentation Used: High-pressure thermowell assemblies with RTDs or thermocouples rated for extreme conditions, integrated into DCS systems with alarm and interlock capabilities. - Slurry Transport Lines
Purpose: Detect temperature changes to prevent settling, monitor viscosity, and protect against freeze conditions in slurry pipelines.
Instrumentation Used: Clamp-on RTDs or insertion-style thermocouples, often in rugged housings with remote transmitters for hazardous or remote locations. - Crushing and Conveying Systems
Purpose: Monitor bearing, motor, and gearbox temperatures to prevent overheating and mechanical failure in crushers and conveyor belts.
Instrumentation Used: Embedded RTDs or surface-mounted thermocouples with alarm relays or temperature switches for shutdown protection. - Smelting and Furnace Operations
Purpose: Control melt zone temperatures and ensure safe furnace operation during metal extraction and refining.
Instrumentation Used: High-range thermocouples (Type B, R, or S) used in refractory-lined wells or immersion assemblies. Data is transmitted to furnace control systems for real-time adjustment. - Environmental and Worker Safety Monitoring
Purpose: Track ambient temperatures in underground tunnels and high-temperature work zones to maintain safe operating conditions.
Instrumentation Used: Digital temperature gauges or thermistor-based sensors with wireless transmitters and integration into mine ventilation or safety systems.
Data Center Applications
In data centers, precise temperature monitoring is essential for maintaining system uptime, reducing energy costs, and protecting critical IT infrastructure. With increasing server densities and heat loads, modern facilities depend on accurate, real-time thermal data to optimize cooling strategies and prevent hardware failures. Below are key applications and the instrumentation used:
- Rack-Level Temperature Monitoring
Purpose: Monitor inlet and exhaust air temperatures at the server rack level to detect thermal hotspots and ensure consistent cooling across rows.
Instrumentation Used: Digital temperature sensors or thermistor probes installed in rack-mounted units or on blanking panels. Often networked via Modbus, BACnet, or SNMP for integration into DCIM or BMS platforms. - CRAC and CRAH Unit Control
Purpose: Maintain precise temperature setpoints for Computer Room Air Conditioners (CRAC) or Air Handlers (CRAH) to ensure proper air supply and return conditions.
Instrumentation Used: High-resolution RTDs or digital sensors placed at air intakes and return ducts. Paired with PID controllers or BMS-controlled actuators to regulate cooling output. - Underfloor Plenum and Aisle Monitoring
Purpose: Track airflow temperatures in raised floor plenums and cold/hot aisle containment zones to manage airflow distribution and eliminate recirculation.
Instrumentation Used: Compact thermistors or digital sensors on mounting rails or support structures, feeding real-time data to airflow balancing or optimization systems. - Chilled Water System Monitoring
Purpose: Ensure efficient operation of chilled water loops used in data center cooling infrastructure, including air handlers and in-row cooling units.
Instrumentation Used: Insertion-style RTDs or thermocouples placed in supply and return lines. Data is used for load tracking, pump control, and efficiency analytics. - Liquid Cooling and Rear Door Heat Exchangers
Purpose: Control coolant loop temperatures in direct-to-chip cooling systems or rear door heat exchangers to protect high-density computing hardware.
Instrumentation Used: RTDs or thermistors embedded in liquid manifolds or quick-connect fittings, integrated with cooling distribution unit (CDU) controllers. - Power Distribution Equipment
Purpose: Monitor transformer, UPS, and PDU temperatures to detect overheating and prevent electrical faults.
Instrumentation Used: Surface-mount RTDs or thermocouples with alarm relays or smart transmitters. Often tied into predictive maintenance or facility monitoring systems. - Ambient and Redundancy Monitoring
Purpose: Provide room-level temperature monitoring and redundancy in critical spaces to prevent blind spots in thermal coverage.
Instrumentation Used: Wall-mounted digital temperature gauges or wireless sensors with battery backup, reporting data to cloud-based dashboards or local control systems.
Terms & Definitions
Accuracy
The degree to which a temperature measurement matches the true or accepted reference value. Critical for process control and compliance.
Bimetallic Strip
A mechanical sensing element made from two metals with different thermal expansion rates, used in temperature switches and gauges to produce mechanical movement with temperature change.
Capillary System
A small-diameter tube connecting a remote sensing bulb to a dial mechanism. Commonly used in gas-actuated and liquid-filled gauges for distant temperature indication.
Cold Junction Compensation
An electronic correction applied in thermocouple measurement to account for the temperature at the reference (cold) junction, ensuring accurate readings.
Controller (Temperature Controller)
A device that maintains a process temperature near a setpoint by regulating heating or cooling outputs. Includes types such as on/off, proportional, and PID.
Derivative Control (D)
The "D" in PID control, which predicts future error based on the rate of temperature change. Used to dampen system response and reduce overshoot.
Digital Temperature Gauge
A temperature display that uses electronic sensors and a digital readout for precise, easy-to-read temperature indication.
Drift
A gradual deviation in sensor output over time, often due to aging, contamination, or environmental stress. Regular calibration minimizes drift impact.
Filled System
A sensing system (liquid or gas-filled) used in remote gauges and switches, where expansion/contraction of the medium transmits temperature changes to a display.
HART Protocol
A hybrid analog-digital communication protocol used with smart transmitters. Allows remote calibration, diagnostics, and configuration over a 4–20 mA signal line.
Hysteresis
A deliberate difference between a switch's turn-on and turn-off temperature points to prevent rapid cycling and improve system stability.
Limit Controller
A safety device that interrupts a process if temperature exceeds predefined safe operating limits. Commonly used in SIL-rated safety instrumented systems.
On/Off Control
The simplest control strategy where output is either fully on or fully off, depending on whether the measured temperature is above or below the setpoint.
PID Controller
A control algorithm that uses proportional, integral, and derivative terms to regulate temperature with high precision and minimal error.
Proportional Control (P)
A control method where output changes in proportion to the temperature deviation from the setpoint. Provides smoother control than on/off switching.
Ramp/Soak Profile
A programmed sequence in which temperature is increased or decreased (ramp) and then held constant (soak) for a set time. Common in thermal processing applications.
RTD (Resistance Temperature Detector)
A temperature sensor that changes resistance with temperature, most commonly using platinum. Known for high accuracy and repeatability.
Sensor Element
The component within a temperature sensor (e.g., RTD element, thermocouple junction) that physically responds to temperature changes.
Setpoint
The target temperature a controller is programmed to maintain in a process.
SIL (Safety Integrity Level)
An international standard classification (IEC 61508/61511) describing the reliability of safety systems. SIL-rated devices are certified for critical safety applications.
Span
The difference between the lowest and highest measurable or controllable temperatures in a given system or device.
Thermistor
A type of temperature sensor made from semiconductor materials with high resistance-temperature sensitivity. Used in compact and cost-sensitive applications.
Thermocouple
A sensor formed by joining two dissimilar metals, generating a voltage proportional to temperature difference. Common in high-temperature applications.
Thermowell
A protective sheath that allows temperature sensors to be inserted into a process without direct exposure, enabling safe sensor replacement and longer life.
Transmitter (Temperature Transmitter)
A device that converts a temperature sensor signal (RTD, thermocouple) into a standardized output, such as 4–20 mA or digital protocol, for monitoring or control systems.
Frequently Asked Questions
Technologies
Temperature Sensors
- Thermocouples
- RTD Sensors
- Camera Sensors
- Filled Bulb Sensors
- Thermowells
Temperature Transmitters
- Analog Transmitters
- Digital Transmitter
Temperature Switches
- Mechanical Switches
- Electronic Switches
Temperature Gauges
- Bimetallic Temperature Gauges
- Gas-Actuated Temperature Gauges
- Liquid-Filled / Vapor-Tension Gauges
- Digital Temperature Gauges
- Infrared Temperature Gauges
Temperature Controllers
- On/Off Temperature Controllers
- Proportional (P) Controllers
- Proportional-Integral (PI) Controllers
- Proportional-Integral-Derivative (PID) Controllers
- Programmable / Multi-Loop Controllers
- Safety Limit Controllers (High-Limit / Low-Limit)
Resources
- Thermocouple Tables
- RTD Tables
Brands We Recommend
Toll Free 
